A manufacturer is awarded an enormous contract. Monthly production requirements rise, but the facility does not suddenly gain floor space, experienced employees or working hours during the daytime. It is possible to add another shift temporarily, but it may create new labor as well as training, supervision and quality-control regulations.
Image credit: automatedsolutions.com.au
Situations like this reveal an important purpose of robotic automation. Robotics is not just replacing humans with machines. It’s a tool that can modify the methods that manufacturers employ to use their production capacity.
Examine the Seconds That Change Between Products
Manufacturing inefficiency doesn’t have to be dramatic. For instance, suppose an operator is spending 15 seconds positioning a component, another 10 seconds applying material, and then a few seconds moving it to the next operation. With a single component the difference is insignificant. If repeated thousands of times the seconds could increase production by a significant amount.
It’s the same for waste materials. A small amount of excess coating or dispensing material that is multiplied across a high-volume production run can become a meaningful expense.
Companies that are thinking about robotic automation Australia could benefit from looking at these small routine losses before they choose the equipment they will purchase. The analysis conducted by ASA’s Needs Analysis is designed to find bottlenecks, quality issues, waste, as well as other limitations to process that could influence an automation project.
The robot should fit the procedure around it.
Selecting a robot is only one decision in engineering. The system might also require guarding, tools, controls, sensors, conveyors, fixtures, electrical integration, and communication with existing production equipment. Engineers should think about the reach, payload and how the robot will be able to move and interact within its surroundings.
ASA provides concepts development, design, CAD simulation, and offline programming as part of its plan to FANUC’s robotic automation. The digital simulation lets engineers analyze configurations, estimate cycles times, and to test the system prior to making it operational on the customer’s floor. It’s especially useful when there’s a finite area or new robotics has to integrate with the production line.
Painting and Dispensing demonstrates why Repetability is Important
Some manufacturing processes illustrate the benefits of controlled movement especially well. Imagine coating hundreds of components. The end goal isn’t simply completing each component quickly. The distance, movement, speed, and the application must be managed starting from the beginning of the production process to the end.
ASA has specialists who work on painting and dispensing applications across various industries, including automotive and aerospace. Industrial robotic automation in these settings allows for repeatable motions while limiting exposure of employees to physically demanding procedures or ones that may be hazardous.
The reduction in waste and the improvement in productivity could be achieved through better control.
Even after the installation, the system still requires users
Automation doesn’t eliminate the need for skilled manufacturing. Automation transforms the skills required to manage and control the process.
Employees must be taught to operate equipment in a safe manner in order to identify any abnormalities or malfunctioning components, and perform necessary maintenance. Production requirements can alter, which means that processes and programs may require adjustments later on.
ASA provides on-site training covering programming, safe operation, troubleshooting, as well as electrical and mechanical maintenance. They also provide servicing and support to check the condition of equipment, and dealing with wear and tear throughout the life of the system.
Capacity refers to more than Being able to work faster
In Australia, increasing capacity for production is not always about adding workers to repetitive tasks or buying larger structures. It’s often better to inquire about whether the production process could be redesigned.
ASA has developed and integrated automation systems in Australia since 2002. We also provide support for projects abroad. The approach combines needs analysis, engineering, simulation, FANUC robot integration Training, and servicing.
Automating just for the sake of it isn’t the main goal. A system worthy of the gold it’s worth will offer tangible benefits to a manufacturer, such as greater reliability, higher quality process, more secure processes and less waste.